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FOLDING LADDER
Manual for Cat D1 1R DozerComplete with Wrap-around Walkways
PSA-D11R-F/L & RHWW 5-4-13a
Model No.PSA-D11R-F/L & RH WW Serial No.:D11R-RHW - ~Date Manufactured: Oct. 2011
FOLDING LADDERCaterpillar D1 1R Dozer
Pg2PSA-D11R-F/L & RHWW 5-4-13a
CONTENTS
Page 3 Section 1 Installation and Mounting instructionsInstallation Drawings
10 Section 2 Recommended Maintenance procedure
11 Section 3 Operating Procedure
Section 4 Drawings and Repair Parts lists
12 4 Assembly Complete
13 4-1 Ladder AssemblyParts List
14 4-2 Landing Assembly LHS (+ NG Version)Parts List
18 4-3 Landing Assembly RHS (+ NG Version)Parts List
22 4-4 Landing Assembly Rear (+ NG Version)Parts List
26 4-5 Spreader AssemlyParts List
28 4-6 Drive Unit AssemblyParts List
30 4-7 PROP AssemblyParts List
31 4-8 Hydraulic CylinderValve DiagramParts List
33 4-9 Power PackParts List
36 4-10 Electrical Controls Parts List
Material Kit Supplied
Wiring Diagrams
FOLDING LADDERCaterpillar D1 1R Dozer
Section 1 Installation Instruction Drawings
Pg3PSA-D11R-F/L & RHWW 5-4-13a
PROCEDURE (Mounting blocks)
See Drawing 22 521 (Page 4)
1 Remove grille plates from the rear of both mudguards.Remove the light and/or horn from the rear of the left-side mudguard.Draw out wiring for future re-use.
2 Weld the Mounting Pads to the rear of the mudguards, in the corners made by the mudguard top plate and vertical inner plate, and in the corner made by the rolled outer edge of the mudguard top plate. All the rear mounting pads fit hard against the folded rear mudguard infill. All these mounting pads have bevelled edges to clear existing welds in the corners.
3 Measure forward from the back surfaces of the rear mounting pads and down from the top surface of the mudguard decks to locate the side mounting pads. Weld these mounting pads in position.
See page 5 for further Procedure.
NOTEFollow all on-site/Mine lif ting and safety procedures when inst allingPower S tep Landings to Dozer .
FOLDING LADDERCaterpillar D1 1R Dozer
Installation and Mounting Instructions 22 521
Pg4PSA-D11R-F/L & RHWW 5-4-13a
FOLDING LADDERCaterpillar D1 1R Dozer
Installation and Mounting InstructionsSee Drawings Page 6,7 and 8
Pg5PSA-D11R-F/L & RHWW 5-4-13a
PROCEDURE
1. Fit Mounting Blocks per Drg 22 521
2. Per View 2, Spreader Plate: Fit Spreader Plate 22 780 to rear mounting blocks. UseWasher Plates and washers under bolt heads - ensure maximum engagement of bolt threads in blind threaded holes. Washer Plates not shown in most Views in this drawing.
3. Fit Isolator Brackets: 21 930 (See Views A,2 & 3 ). Fit Side Landing Beam 22 970 with Ladder Shaft and Drive already assembled,supported byIsolators.
4. Fit Ladder. Using Spacers (within Actuator Cylinder Mounting 21 954), adjust drive so gears are not loaded when ladder is lowered.Clamp PROP Mtg Beams in position shown in View 1 and mount PROP 21 945Adjust position so that, with PROP attached to Isolators ladder gear drive is not loaded when ladder is fully raised. Attach PROP System Mounting Frame 21 987atop cabin, on ROPS unless similar is already fitted by customer.Weld Beams to Frame, 6cfw where visible from above
5. Per Views 1,4 & 6. Complete Assembly and PROP System.
6. Per View 4,5 & 6: Fit Rear Walkway. Fit Handrails.
NOTES.The drive, ladder stops and/or PROP system are to be adjusted so that in both the Ladder Up (Travel) position and Ladder Down (Climb) position, the actuator gears and cylinder are not loaded.
FOLDING LADDERCaterpillar D1 1R Dozer
Section 1 Installation Instruction Drawings - 22 520 Page 1
Pg6PSA-D11R-F/L & RHWW 5-4-13a
FOLDING LADDERCaterpillar D1 1R Dozer
Section 1 Installation Instruction Drawings - 22.520 Page 2
Pg7PSA-D11R-F/L & RHWW 5-4-13a
FOLDING LADDERCaterpillar D1 1R Dozer
Section 1 Installation Instruction Drawings - 22.520 Page 3
Pg8PSA-D11R-F/L & RHWW 5-4-13a
FOLDING LADDERCaterpillar D1 1R Dozer
Section 1 Installation and Mounting Instructions (cont.)Maintenance Notes
Pg9PSA-D11R-F/L & RHWW 5-4-13a
NOTEFollow all on-site/Mine lif ting and safety procedures when inst allingPower S tep Landings to Dozer .
WARNINGRaising the POWER STEP Ladder by external means can create a vacuum in thehydraulic cylinder and create the opportunity to allow air into the hydraulic system,defeating the inherent safety features of the POWER STEP.This must be avoided, to maintain safe operation of the POWER STEP.
In instances where the use of external means to raise the Ladder must be used, pleasefollow the following instructions:
Loosen hard plumbed hydraulic lines on cylinder side of lock valve on cylinder.Raise Ladder by available means.Note: Make necessary arrangements to collect displaced oil, and be aware that air entersthe piston side of the cylinder as platform is raised.Lock in raised position.Re-tighten hydraulic fittings.SECURE THE LADDER IN THE RAISED POSITION, MECHANICALLY, CHAIN &TAGOUT THE POWER STEP
To recommission the POWER STEP:
Loosen hydraulic fittings on cylinder side of lock valve.Note: Collect displaced oil.Lower Ladder to lowest position, using alternate safety approved means, fully retractingcylinder. Ensure all personnel are clear of step radius.Operate electrical control switch to purge air from the hydraulic line systems, lock valveand cylinder.Tighten the hydraulic fittings either side of lock valve to restriction fitting.Cycle step unloaded several times to purge all air from hydraulic system.The Power Step will not operate correctly if there is any air in the hydraulic circuit (due tothe incorrect operation of the lock valve).
DailyVisually check st airway and structure for damage, loose component s, handrails, etc.
Check for hydraulic oil leaks from hydraulic cylinders, plumbing and hoses.
Notify the appropriate supervisor for any observed damage or malfunction.
500 HoursGrease the nipples on the rotation shaft and sector gears.
Check main mounting bolts for torque.
Check hydraulic oil level in power pack and top up as necessary. (Stairway in raisedposition).
Top up using same hydraulic oil as used in hydraulics of machine.Thoroughly check all electrical wiring for damage, replace as necessary.
Repeat daily check as above
5000 HoursChange hydraulic oil in tank of hydraulic power pack (5.0 litres)
It is recommended that the same hydraulic oil be used in the power pack as the hydraulics of the machine.
Grease 4 grease nipples on rotation shaft and sector gears, all of these are accessible with the stairway lowered, and accessed from under the stairway.
Check and inspect all main bolts on stairway system.Retorque if required.
Repeat daily check as above
FOLDING LADDERCaterpillar D1 1R Dozer
Section 2 Recommended Maintenance Procedure
Pg10PSA-D11R-F/L & RHWW 5-4-13a
FOLDING LADDERCaterpillar D1 1R Dozer
Section 3 Operating Procedure
Pg11PSA-D11R-F/L & RHWW 5-4-13a
To Lower Ladder (from the machine)Position machine in a level, safe area, away from the work face, whenever possible.Apply park brake and lower engine speed to idle.Check that the area below the Ladder Access System is clear of people and obstacles, and lower ladder by operating the two position electrical switch adjacent to the ladder, to the down position by pressing the switch down.Hold the switch in the down position until ladder is fully lowered.If the Dozer is parked on uneven ground, the bottom of the stairway may touch the ground before the ladder is in the fully lowered position.Should this occur, descend the ladder with caution.
To Raise LadderAscend the ladder onto the landing of the Dozer.Ensure the area around the ladder is clear of people and standing to the side, clear of the area the handrails and ladder raises into, operate the electrical switch to the raise position (up).Hold the switch in the up position until the ladder is in the fully raised position.The ladder is now raised and stored.
OPERATING NOTES
NOTE: FLOW CONTROL VALVE ADJUSTMENT:The valve should be positioned to restrict the flow and speed of the Power Step whenlowering. Adjust the knob on top of the valve by turning left or right (clockwise) when thestep is being lowered, until it is lowering at a safe and reasonable speed.
When it is adjusted, lock the adjusting knob by tightening the grub screw located on theside of the knob.
NOTE: MAGNETIC 'GO' SWITCH ADJUSTMENT:The switch target trigger area is located on the opposite side and end from the cable entrypoint on the switch. Once it is mounted to the switch bracket, adjust the switch in or outfrom the stair steel trigger point, to be within 3mm - 10mm from touching each other whenthe stair is in the desired rest position.[DO NOT EXCEED 10MM DISTANCE BETWEEN THE SWITCH AND STRIKER PLATE].Test by raising and lowering the Power Step a couple of times and adjust again ifnecessary.
FOLDING LADDERCaterpillar D1 1R Dozer
Section 4 Assembly Complete
Pg12PSA-D11R-F/L & RHWW 5-4-13a
FOLDING LADDERCaterpillar D1 1R Dozer
Section 4-1 Ladder Assembly
Pg13PSA-D11R-F/L & RHWW 5-4-13a
Item Part No. Part Name Qty
1
2
3
4
5
6
7
8
9
10
PS-21924
PS-21977
PS-21958
PS-21926-01
PS-21926-02
PS-21926-03
CPS-M12X45
CPS-M12X30
CPS-M12NZP
CPS-M12WH
LADDER & HANDRAIL FABRICATION
ROTATION SHAFT
PINION ASSEMBLY
LADDER SHAFT PIVOT BUSH-MIDDLE
LADDER SHAFT PIVOT BUSH-NON DRIVE END
LADDER SHAFT PIVOT BUSH- DRIVE END
BOLT-M12 x 45
BOLT-M12 x 30
NUT-M12
WASHER-M12
1
1
1
1
1
1
8
8
16
32
FOLDING LADDERCaterpillar D1 1R Dozer
Section 4-2 Landing Assembly LHS. PS-22786A-D11RSee Parts list Page 15
Pg14PSA-D11R-F/L & RHWW 5-4-13a
FOLDING LADDERCaterpillar D1 1R Dozer
Section 4-2 Landing Assembly LHS. PS-22786A-D11RSee Drawing Page 14
Pg15PSA-D11R-F/L & RHWW 5-4-13a
Item Part No. Part Name Qty
1
2
2A
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
PS-22786
PS-22787A
PS-22787B
PS-21932
PS-21930A
PS-21976
PS-21941-02
PS-21941-06
PS-21933
PS-21925
PS-22005
PS-22789-01
PS-22789-02
PS-22789-03
PS-22785-04
CPS-M12X75ZP
CPS-M12X65ZP
CPS-M12X35ZP
CPS-M12X30ZP
CPS-M12X25ZP
CPS-M8X35ZP
CPS-M12NZP
CPS-1/2”NN
CPS-M8NN
CPS-M12WH
CPS-M8WH
LANDING ASSY
HANDRAIL- LHS-FRONT
HANDRAIL- LHS-REAR
ISOLATOR PIN BRACKETS
ISOLATOR MOUNTING ASSY
FRONT PIVOT PIN BRACKET
ANTI VIBRATION BEARING
RUBBER BUSH
ISOLATOR BUSH PIN
MIDDLE BEARING MOUNTING
ISOLATED HANDRAIL LINK ASSY
MOUNTING BAR
CLAMP BAR
ISOLATOR ELEMENT
SIDE MOUNTING PAD
BOLT-M12 x 75
BOLT-SOCKET HEAD-M12 x 65
BOLT-M12 x 35
BOLT-M12 x 30
BOLT-M12 x 25
BOLT-M8 x 35
NUT-M12
NUT-NYLOC-1/2”UNC
NUT-NYLOC-M8
WASHER-HARDENED-M12
WASHER-HARDENED-M8
1
1
1
2
6
1
2
2
2
1
1
1
2
1
2
2
2
28
12
20
8
30
4
8
98
16
Pg16PSA-D11R-F/L & RHWW 5-4-13a
FOLDING STAIRWAYCaterpillar D1 1R Dozer
Section 4-2 Landing Assembly LHS. PS-22786A-D11R-NGSee Parts Page 17 Updated Handrails
FOLDING STAIRWAYCaterpillar D1 1R Dozer
Section 4-2 Landing Assembly LHS. PS-22786A-D11R-NGSee Drawing Page 16
Pg17PSA-D11R-F/L & RHWW 5-4-13a
Item Part No. Part Name Qty
1
2
2A
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
PS-22786
PS-22787A-NG
PS-22787B-NG
PS-21932
PS-21930A
PS-21976
PS-21941-02
PS-21941-06
PS-21933
PS-21925
PS-HRI-A06
PS-22785-04
CPS-M12X65ZP
CPS-M12X35ZP
CPS-M12X30ZP
CPS-M12X25ZP
CPS-M8X35ZP
CPS-M12NZP
CPS-1/2”NN
CPS-M8NN
CPS-M12WH
CPS-M8WH
LANDING ASSY
HANDRAIL- LHS-FRONT -NEW GEN
HANDRAIL- LHS-REAR-NEW GEN
ISOLATOR PIN BRACKETS
ISOLATOR MOUNTING ASSY
FRONT PIVOT PIN BRACKET
ANTI VIBRATION BEARING
RUBBER BUSH
ISOLATOR BUSH PIN
MIDDLE BEARING MOUNTING
HANDRAIL POST CLAMP
SIDE MOUNTING PAD
BOLT-SOCKET HEAD-M12 x 65
BOLT-M12 x 35
BOLT-M12 x 30
BOLT-M12 x 25
BOLT-M8 x 35
NUT-M12
NUT-NYLOC-1/2”UNC
NUT-NYLOC-M8
WASHER-HARDENED-M12
WASHER-HARDENED-M8
1
1
1
2
6
1
2
2
2
1
4
2
2
36
12
20
8
30
4
8
98
16
Updated Handrails
Pg18PSA-D11R-F/L & RHWW 5-4-13a
FOLDING STAIRWAYCaterpillar D1 1R Dozer
Section 4-2 Landing Assembly RHS. PS-22784A-D11RSee Parts List Page 19
FOLDING LADDERCaterpillar D1 1R Dozer
Section 4-3 Landing Assembly RHS. PS-22784A-D11RSee Drawing Page 18
Pg19PSA-D11R-F/L & RHWW 5-4-13a
Item Part No. Part Name Qty
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
PS-22784
PS-22788
PS-21932
PS-21930A
PS-21933
PS-22005-02
PS-22005-03
PS-22789
PS-21927-04
CPS-M12X75ZP
CPS-M12X35ZP
CPS-M12X25ZP
CPS-M12NZP
CPS-1/2”NN
CPS-M12WH
LANDING ASSEMBLY RHS
HANDRAIL RHS
ISOLATOR PIN BRACKET
ISOLATOR MOUNTING ASSY
ISOLATOR BUSH PIN
CLAMP PLATE
ISOLATOR RUBBER
HANDRAIL ISOLATOR STYLE II
SIDE MOUNTING PAD
BOLT-M12 x 75
BOLT-M12 x 35
BOLT-M12 x 25
NUT-M12
NUT- NYLOC-1/2” UNC
WASHER-HARDENED-M12
1
1
2
6
2
2
2
1
2
20
20
22
4
68
2
FOLDING STAIRWAYCaterpillar D1 1R Dozer
Section 4-3 Landing Assembly RHS. PS-22784A-D11R-NGSee Parts List Page 21
Pg20PSA-D11R-F/L & RHWW 5-4-13a
Updated Handrails
FOLDING STAIRWAYCaterpillar D1 1R Dozer
Section 4-3 Landing Assembly RHS. PS-22784A-D11R-NGSee Drawing Page 20
Pg21PSA-D11R-F/L & RHWW 5-4-13a
Updated Handrails
Item Part No. Part Name Qty
1
2
3
4
5
6
7
8
9
10
11
12
PS-22784
PS-22788
PS-21932
PS-21930A
PS-21933
PS-HRI-A06
PS-21927-04
CPS-M12X35ZP
CPS-M12X25ZP
CPS-M12NZP
CPS-1/2”NN
CPS-M12WH
LANDING ASSEMBLY RHS
HANDRAIL RHS- NG
ISOLATOR PIN BRACKET
ISOLATOR MOUNTING ASSY
ISOLATOR BUSH PIN
HANDRAIL POST CLAMP (CLAMP ASSY)
SIDE MOUNTING PAD
BOLT-M12 x 35
BOLT-M12 x 25
NUT-M12
NUT- NYLOC-1/2” UNC
WASHER-HARDENED-M12
1
1
2
6
2
4
2
20
20
20
4
64
FOLDING LADDERCaterpillar D1 1R Dozer
Section 4-4 Landing Assembly Rear PS-22782ASee Parts list Page 23
Pg22PSA-D11R-F/L & RHWW 5-4-13a
FOLDING LADDERCaterpillar D1 1RN Dozer
Section 4-4 Landing Assembly Rear PS-22782ASee Drawing Page 22
Pg23PSA-D11R-F/L & RHWW 5-4-13a
Item Part No. Part Name Qty
1
2
3
4
5
6
7
8
9
10
11
12
13
PS-22782
PS-22783
PS-21928-R
PS-21928-L
PS-21990
PS-M16X50ZP
PS-M16X30ZP
PS-M12X35ZP
PS-M12X30ZP
CPS-M16NZP
CPS-M12NZP
CPS-M16WH
CPS-M12WH
LANDING - REAR
HANDRAILS - REAR
REAR LANDING BRACKET -RHS
REAR LANDING BRACKET -LHS
RIPPER LIGHT BRACKET
BOLT-M16 x 50
BOLT-M16 x 30
BOLT-M12 x 35
BOLT-M12 x 30
NUT-M16
NUT-M12
WASHER-HARDENED-M16
WASHER-HARDENED-M12
1
1
3
1
1
8
8
30
2
8
32
24
64
FOLDING STAIRWAYCaterpillar D1 1R Dozer
Section 4-4 Landing Assembly Rear PS-22782A-NG Updated HandrailsSee Parts List Page 25
Pg24PSA-D11R-F/L & RHWW 5-4-13a
FOLDING STAIRWAYCaterpillar D1 1R Dozer
Section 4-4 Landing Assembly Rear S-22782A-NG Updated HandrailsSee Drawing Page 24
Pg25PSA-D11R-F/L & RHWW 5-4-13a
Item Part No. Part Name Qty
1
2
3
4
5
6
7
8
9
10
11
12
13
PS-22782
PS-22783
PS-21928-R
PS-21928-L
PS-21990
PS-M16X50ZP
PS-M16X30ZP
PS-M12X35ZP
PS-M12X30ZP
CPS-M16NZP
CPS-M12NZP
CPS-M16WH
CPS-M12WH
LANDING - REAR
HANDRAILS - REAR - NG
REAR LANDING BRACKET -RHS
REAR LANDING BRACKET -LHS
RIPPER LIGHT BRACKET
BOLT-M16 x 50
BOLT-M16 x 30
BOLT-M12 x 35
BOLT-M12 x 30
NUT-M16
NUT-M12
WASHER-HARDENED-M16
WASHER-HARDENED-M12
1
1
3
1
1
8
8
30
2
8
32
24
64
FOLDING LADDERCaterpillar D1 1R Dozer
Section 4-5 Spreader Assembly See Parts List Page 27
Pg26PSA-D11R-F/L & RHWW 5-4-13a
FOLDING LADDERCaterpillar D1 1R Dozer
Section 4-5 Spreader Assembly See Drawing Page 26
Pg27PSA-D11R-F/L & RHWW 5-4-13a
Item Part No. Part Name Qty
1
2A
2B
3
4
5A
5B
6
7
8
9
10
11
12
13
14
15
16
17
18
19
PS-22780
PS-21931 98
PS-21931 97
PS-21931 99
PS-21929
PS-22785 01A
PS-22785-01B
PS-22785-02
PS-22785-03
PS-22785-06
PS-22785-05
PS-21983
PS-21930A
PS-M20X60ZP
PS-M20X45ZP
CPS-M12X40ZP
CPS-M12X25ZP
CPS-M12NZP
CPS-1/2”NN
PS-M20WH
CPS-M12WH
SPREADER
ISOLATOR PIN BRACKET-OUTER LEFT
ISOLATOR PIN BRACKET-OUTER RIGHT
ISOLATOR PIN BRACKET-INNER
REAR LANDING POST
REAR TOP INNER MOUNTING BLOCK-LHS
REAR TOP INNER MOUNTING BLOCK-RHS
REAR LOWER INNER MOUNTING BLOCK
REAR OUTER MOUNTING BLOCK
WASHER PLATES
WASHER PLATES
ISOLATOR BUSH PIN
ISOLATOR MOUNTING ASSY
BOLT-M20 x 60
BOLT-M20 x 45
BOLT-M12 x 40
BOLT-M12 x 25
NUT-M12
NUT-NYLOC-1/2” UNC
WASHER-HARDENED-M20
WASHER-HARDENED-M12
1
1
1
2
1
1
1
2
2
2
4
4
12
8
4
2
40
2
8
12
52
FOLDING LADDERCaterpillar D1 1R Dozer
Section 4-6 Drive Unit AssemblySee Parts list Page 29
Pg28PSA-D11R-F/L & RHWW 5-4-13a
FOLDING LADDERCaterpillar D1 1R Dozer
Section 4-6 Drive Unit AssemblySee Drawing Page 28
Pg29PSA-D11R-F/L & RHWW 5-4-13a
Item Part No. Part Name Qty
1
2
3
4
5
6
6A
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
PS-63014
PS-21974
PS-21959
PS-21984
PS-21954
PS-21991-02
PS-21991-01
PS-61006-2
PS-21940-03
PS-21959-09
PS-21959-08
PS-21959-05
PS-21959-06
PS-M24X120ZP
CPS-M20X65ZP
CPS-M12X70ZP
CPS-M12X25ZP
CPS-M10X30ZP
CPS-M10X15ZP
CPS-M5X15ZP
PS-M24NN
PS-M20NZP
CPS-M12NZP
CPS-M12NN
CPS-M5NN
CPS-M24WH
CPS-M20WH
CPS-M12WH
CPS-M10WH
CPS-M5WH
HYDRAULIC CYLINDER (Refer Page 22)
DRIVE MOUNTING FRAME
SECTOR GEAR
DRIVE GUARD
ACTUATOR CYL. MOUNTING ASSEMBLY
MOUNTING BAR-PROXIMITY SWITCH
STRIKER
GREASE NIPPLE M6 STR.
PIVOT PIN KEEPER PLATE
SECTOR GEAR BUSH
SECTOR GEAR HUB
CLAMP RING
SPACER RING
BOLT-M24 x 120
BOLT-M20 x 65
BOLT-M12 x 70
BOLT-M12 x 25
BOLT-M10 x 30
BOLT-M10 x 15
BOLT-M5 x 15
NUT-NYLOC-M24
NUT-M20
NUT-M12
NUT-NYLOC-M12
NUT-NYLOC-M5
WASHER-HARDENED-M24
WASHER-HARDENED-M20
WASHER-HARDENED-M12
WASHER-HARDENED-M10
WASHER-HARDENED-M5
1
1
1
1
1
1
1
4
1
2
1
1
1
2
4
8
10
4
4
6
2
4
14
3
6
4
8
20
12
12
FOLDING LADDERCaterpillar D1 1R Dozer
Section 4-7 PROP Assembly
Pg30PSA-D11R-F/L & RHWW 5-4-13a
Item Part No. Part Name Qty
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
PS-21987
PS-21945
PS-21987-16
PS-21987-14
PS-21987-13
PS-21930A
PS-40003
PS-21987-11
PS-21987-10
CPS-M12X120ZP
CPS-M12X50ZP
CPS-M12X40ZP
CPS-M12X25ZP
CPS-M12NZP
CPS-M12NN
CPS-M10NZP
CPSM12WH
CPS-M10WH
PROP MOUNTING FRAME
PROP
ROOF BUTTON
BOLTING PAD
SPACER
ISOLATOR MOUNTING ASSY
BUFFER
ISOLATOR PAD
PROP SUPPORT SPREADER
BOLT-M12 x 120
BOLT-M12 x 50
BOLT-M12 x 40
BOLT-M12 x 25
NUT-M12
NUT-NYLOC-M12
NUT-M10
WASHER-HARDENED-M12
WASHER-HARDENED-M10
1
1
2
2
2
4
4
4
1
4
8
8
6
16
4
4
46
4
FOLDING LADDERCaterpillar D1 1R Dozer
Section 4-8 Hydraulic Cylinder PS-63014-AHIncl. Items 1A,1B,2,3,4,5,6,7,8,9,11,12,13.
Pg31PSA-D11R-F/L & RHWW 5-4-13a
Item Part No. Part Name Qty
1A
1B
1S
2
3
4
5
6
7
8
9
10
11
12
13
PS-63014A
PS-63014-P
PS-63011K
PS-63201
PS-61158-0.30
PS-61154
PS-61157
PS61163
PS-61160
PS-60047
PS-60051-2.8
PS-61151
PS-61145
PS-61153
PS-60050-2.8
HYDRAULIC CYLINDER
PIN - CYLINDER- (WITH RETAINER)
SEAL KIT (NOT SHOWN)
VALVE - PILOT OPERATED LOCKING
FITTING - RESTRICTION 90 DEG
FITTING - ELBOW- O RING 1/4BSPPx9/16”JIC
FITTING - O RING 1/4BSPPx 9/16”JIC
REDUCER JIC x BSPP
TUBE
FERRULES/NUTS 2 x each
HOSE- HYDR. (9/6”JIC SWIVEL FITTING 2.8M)
FITTING-ELBOW 7/16”JIC
FITTING-SWIVEL 9/16”JIC
FITTING-O RING 1/4”BSP x 7/16”JIC
HYDR. HOSE 7/16” SWIVEL FITTINGS
1
2
1
1
2
1
1
2
2
1
1
1
1
1
1
3
FOLDING LADDERCaterpillar D1 1R Dozer
Section 4-8 Hydraulic Cylinder - Valve DiagramSee also Drawing page 31
Pg32PSA-D11R-F/L & RHWW 5-4-13a
Double Acting Hydraulic System withdirectional Control Valve and Cylinder
Lock Valve
0.030” 0.030”
FOLDING STAIRWAYCaterpillar D1 1R Dozer
Section 4-9 Power Pack PS-80103A-SLDSee Parts List Pg 35
Pg33PSA-D11R-F/L & RHWW 5-4-13a
8
4
13
27
26 6 5 25
6
2 7
10
29
11
16
14
12
3 3024 3A
Hoses showndotted
View B View A
7A
9 9A 8A
FOLDING LADDERCaterpillar D1 1R Dozer
Section 4-9 Power Pack PS-80103A-SLDSee Parts List Pg 35
Pg34PSA-D11R-F/L & RHWW 5-4-13a
15
20
21
23
9
View B
9A
View A
32
33
24
14
19
11
16
28
10
18
31
17
12
NOTE.THE RELIEF PRESSURE OF THE POWERPACK IS TO BE SET TO 2800PSI.IF THE POWERPACK IS REPLACED,THIS RELIEF PRESSURE WILL NEED TO BERESET USING INLINE GAUGES.FAILURE TO DO SO MAY RESULT IN ACCIDENT OR INJURY.
WORKLIGHT 3PIN
BEACON
FOLDING STAIRWAYCaterpillar D1 1R Dozer
Section 4-9 . Power Pack PS-80103A-SLD(Includes Electrical controls & Accessories)See Photos Page 33 & 34
Pg35PSA-D11R-F/L & RHWW 5-4-13a
Item Part No. Part Name Qty
1
2
3
3A
4
5
6
7
7A
8
8A
9
9A
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
PS-80103A-SLD
PS-21107-METAL
PS-80103A
PS-80103-CLAMP
PS-82415
PS-84214
PS-82492
PS-60051-900MM 9/16”
PS-60050-900MM 7/16”
PS-61152
PS-61150
PS-61177
PS-61176
PS-84213
PS-84212
PS-84303
PS-1712080
PS-73012
PS-82493
PS-HD10-5-16P
PS-41010
PS-41011
PS-41012
PS-41013
PS-41014
PS-41023
PS-41024
PS-41041
PS-41019
PS-41017
PS-41018
PS-41016
PS-73010
PS-73009
PS-HD10-3-16P
PS-HD10-5-16P
PS-41032
PS-60051-2.8M
PS-60050-2.8M
POWER PACK ASSEMBLY
MOTOR ENCLOSURE- SEALED
POWER PACK
CLAMP ELECTRIC MOTOR
AUDIBLE ALARM
BRIDGE RECTIFIER
SOLENOID 24V START MOTOR
HYDR. HOSES 9/16”JIC STRAIGHT SWIVEL
HYDR. HOSES 7/16”JIC STRAIGHT SWIVEL
HYDRAULIC FITTING 9/16”
HYDRAULIC FITTING 7/16”
HYDRAULIC FITTING 9/16”
HYDRAULIC FITTING 7/16”
135A CIRCUIT BREAKER
5A CIRCUIT BREAKER
ISOLATION SWITCH- (INCLUDING BRACKET)
SEALED WIRING BOX
TOGGLE SWITCH KIT
BATTERY FEED STUDS
5 PIN SOCKET
DECAL-Battery Isolation
DECAL-Battery Supply C/B-135A
DECAL-Controller Supply C/B-5A
DECAL-Battery Supply-PosItive
DECAL-Battery Supply-Negative
DECAL-Up/Down
DECAL HYDRAULIC-HOSES
DECAL OIL TANK
DECAL BRIDGE RECTIFIER
DECAL SOLENOID
DECAL ALARM
DECAL RAISE/LOWER SWITCH
RUBBER BOOT RED
RUBBER BOOT BLACK
3 PIN SOCKET (PARK BREAK)
5 PIN SOCKET (AUTO-RAISE)
DECAL AUTO-RAISE SOCKET
HYDRAULIC HOSE 9/16” x 2.8M
HYDRAULIC HOSE 7/16” x 2.8M
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
4
2
1
1
1
1
1
Not Shown
Not Shown
FOLDING STAIRWAYCaterpillar D1 1R Dozer
Section 4.10 Electrical Controls
Pg36PSA-D11R-F/L & RHWW 5-4-13a
Cab Harness & EquipmentRefer Wiring Harness Drawings
Proximity Switch AssemblyMounted on Fixed Landing
Control Pendant SwitchMounted on Handrail
7
3
8
4 25 6
1
FOLDING STAIRWAYCaterpillar D1 1R Dozer
Section 4.10 Electrical Controls
Pg37PSA-D11R-F/L & RHWW 5-4-13a
Item Part No. Part Name Qty
1
2
3
4
5
6
7
8
PS-73013
PS-73013-B
PS-77005
PS-77009AR
PS-77004
PS-75430
PS-77002
PS-77003
CONTROL PENDANT SWITCH
CONTROL PENDANT BRACKET
HAND RAIL SWITCH HARNESS
AUTO RAISE HARNESS
CABIN TO SWITCH HARNESS
PROXIMITY SWITCH
CABIN BOX LED LIGHT INDICA TOR
WIRING HARNESS IN CABIN
1
1
1
1
1
2
1
1
Optional only
1 x Optional
WARNING
LOW OR FAULTY BATTERIES WILL VOIDWARRANTY ON THE POWER PACK AND ALLELECTRICAL SWITCHES AND COMPONENTS
Pg38PSA-D11R-F/L & RHWW 5-4-13a
FOLDING LADDERCaterpillar D1 1R Dozer
Section 4.10 Electrical Controls
Material Kit supplied PS-P/PACK-ISO. KIT
LOCTITE 243 TO APPLY ONHYDRAULIC TANK SCREWS
TANK PAD MADE OFRUBBER
2 EACH 3/8" X 1 ¼" BOLTS
4 EACH RUBBERMOUNTS WITHHARDWARE
MALE & FEMALE 7/16AND 9/16 HYDRAULICCAPS FOR THE HOSES
FOLDING LADDERCaterpillar D1 1R Dozer
Section 4.10 Electrical Controls Wiring Diagrams Page 1
Pg39PSA-D11R-F/L & RHWW 5-4-13a
FOLDING LADDERCaterpillar D1 1R Dozer
Section 4.10 Electrical Controls Wiring Diagrams Page 2
Pg40PSA-D11R-F/L & RHWW 5-4-13a
FOLDING STAIRWAYCaterpillar D1 1R Dozer
Section 4.10 Electrical Controls Wiring Diagrams Page 3
Pg41PSA-D11R-F/L & RHWW 5-4-13a
FOLDING STAIRWAYCaterpillar D1 1R Dozer
Section 4.10 Electrical Controls Wiring Diagrams Page 4
Pg42PSA-D11R-F/L & RHWW 5-4-13a
WIRING HARNESS 1
FOLDING STAIRWAYCaterpillar D1 1R Dozer
Section 4.10 Electrical Controls Wiring Diagrams Page 5
Pg43PSA-D11R-F/L & RHWW 5-4-13a
WIRING HARNESS 2